Invisible, light-transmissive display system

ABSTRACT

An invisible, light-transmissive display system with a light resistant material is provided. Substantially invisible holes penetrate through at least a portion of the light resistant material in a predetermined light-transmissive display pattern.

This application is a continuation of U.S. patent application Ser. No.14/280,987, filed May 19, 2014, which is a continuation of U.S. patentapplication Ser. No. 12/973,627, now U.S. Pat. No. 8,735,800, filed Dec.20, 2010, which is a continuation of U.S. patent application Ser. No.11/456,833, now U.S. Pat. No. 7,884,315, filed Jul. 11, 2006, which arehereby incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present invention relates generally to device display systems, andmore particularly to invisible, light-transmissive display systems thatbecome visible when illuminated from behind.

BACKGROUND ART

In the world, of consumer devices, and. particularly consumerelectronics, there is an ever-present demand for improved appearance,improved functionality, and improved aesthetics. Industrial design hasbecome a highly skilled profession that focuses on fulfilling this needfor enhanced consumer product appearance, functionality, and aesthetics.

One area that continually receives great attention for improvement isuser displays. Providing crisp, attractive, unambiguous, and intuitivelyfriendly displays and information for the user is very important in manyconsumer products. However, as consumer products constantly becomesmaller and smaller, and in some cases more and more complex, it becomesincreasingly difficult to present and display user information in amanner that is easy for the user to grasp and understand, but is also inan uncluttered form and appearance that is aesthetically pleasing.

Much of the aesthetic appeal of a consumer product can quickly becompromised if there are too many display elements, or if too muchdisplay area is occupied by display elements that are not needed exceptat particular times. When not needed, these “passive” or unactivateddisplay elements invariably remain visible to the user, even though inthe “off” state. This is not only displeasing from an aestheticstandpoint, but it can be an annoying distraction that interferes withdetection and understanding of other display elements that need to beobserved at a given moment.

Many display elements are illuminated. Some display elements areilluminated continuously; others are illuminated only when appropriateto instruct and guide the user. Display elements that are notcontinuously illuminated can be distracting, or at least aestheticallyobjectionable, when not illuminated (when in the off state) because theystill remain visible in the display area.

For example, one typical such display element is configured fromtransparent plastic inserts that penetrate through the metallic case ofan electronic device, and are smoothly flush with the outer surface ofthe case. Oftentimes, a large number of such always-visible displayelements leads to a cluttered, confusing, and unattractive appearance.In fact, even a single such element, when not illuminated (i.e., in aninactive state), can become an unattractive blotch on an otherwisesmooth and attractive surface.

Less expensive device cases, for example, those made of opaque plasticrather than metal, are often similarly provided with transparent plasticinserts for illuminated display elements. These display elements alsoconflict with a good aesthetic appearance when they are not illuminated.

Also, prior displays using plastic or glass are less durable than metaland are more subject to breaking or cracking.

Additionally, the separate visible inserts utilized by prior techniquessometimes do not fit perfectly in the holes in which they are insertedor formed. Such imperfect fit can invite entry of liquids, dirt, and soforth, undesirably causing yet another disadvantage.

Thus, a need still remains for commercially feasible device displaysystems with improved aesthetics that unobtrusively furnish informationas appropriate but otherwise do not distract or detract from the user'sexperience or the device's performance. Preferably, selected elements ofsuch display systems would additionally become invisible in their offstates.

In view of ever-increasing commercial competitive pressures, increasingconsumer expectations, and diminishing opportunities for meaningfulproduct differentiation in the marketplace, it is increasingly criticalthat answers be found to these problems. Moreover, the ever-increasingneed to save costs, improve efficiencies, improve performance, and meetsuch competitive pressures adds even greater urgency to the criticalnecessity that answers be found to these problems.

Solutions to these problems have been long sought but prior developmentshave not taught or suggested any solutions and, thus, solutions to theseproblems have long eluded those skilled in the art.

DISCLOSURE OF THE INVENTION

The present invention provides an invisible, light-transmissive displaysystem with a light resistant material. Substantially invisible holespenetrate through at least a portion of the light resistant material ina predetermined light-transmissive display pattern.

Certain embodiments of the invention have other aspects in addition toor in place of those mentioned above. The aspects will become apparentto those skilled in the art from a reading of the following detaileddescription when taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a portable computer incorporating an invisible,light-transmissive display system according to the present invention;

FIG. 2A is an enlarged detail from FIG. 1 of status indicators shown inan illuminated state;

FIG. 2B is a view similar to FIG. 2A in which the status indicators arein an unilluminated state;

FIG. 3A is an enlarged detail from FIG. 1 of the caps lock indicatorshown in an illuminated state;

FIG. 3B is a view similar to FIG. 3A in which the caps lock indicator isin an unilluminated state;

FIG. 4A is an enlarged detail from FIG. 1 of the sleep indicator shownin an illuminated state;

FIG. 4B is a view similar to FIG. 4A in which the sleep indicator is inan unilluminated state;

FIG. 5A is a bottom view of the portable computer of FIG. 1;

FIG. 5B is a view similar to FIG. 5A in which the battery statusindicator lights are in an unilluminated state;

FIG. 6A is a view of a personal music player with a surface logo in anilluminated state;

FIG. 6B is a detail from 6A showing the logo in an unilluminated state;

FIG. 7 is an enlarged view of a fragment of light resistant materialhaving an opaque outer surface and incorporating an invisible,light-transmissive display system according to the present invention;

FIG. 8 is a cross-sectional view of the fragment shown in FIG. 7;

FIG. 9 is a view of the structure of FIG. 8 following application of aparticle-containing clear coat into the holes thereof;

FIG. 10 is a view of a fragment structure similar to that in FIG. 9 buthaving individual lights for each of the holes;

FIG. 11 is a view of a fragment structure having a TFT layer alignedwith the individual holes;

FIG. 12 is a view of several representative hole patterns; and

FIG. 13 is a flow chart of a process for manufacturing an invisible,light-transmissive display system in accordance with an embodiment ofthe present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

The following embodiments are described in sufficient detail to enablethose skilled in the art to make and use the invention. It is to beunderstood that other embodiments would be evident based on the presentdisclosure, and that process or mechanical changes may be made withoutdeparting from the scope of the present invention.

In the following description, numerous specific details are given toprovide a thorough understanding of the invention. However, it will beapparent that the invention may be practiced without these specificdetails. In order to avoid obscuring the present invention, somewell-known system configurations and process steps are not disclosed indetail.

Likewise, the drawings showing embodiments of the system aresemi-diagrammatic and not to scale and, particularly, some of thedimensions are for the clarity of presentation and are shown greatlyexaggerated in the drawing FIGs.

Similarly, although the views in the drawings for ease of descriptiongenerally show similar orientations, this depiction in the FIGs. isarbitrary for the most part. Generally, the invention can be operated inany orientation. In addition, where multiple embodiments are disclosedand described having some features in common, for clarity and ease ofillustration, description, and comprehension thereof, similar and likefeatures one to another will ordinarily be described with like referencenumerals.

For expository purposes, the term “horizontal” as used herein is definedas a plane parallel to the plane or surface of the display, regardlessof its orientation. The term “vertical” refers to a directionperpendicular to the horizontal as just defined. Terms, such as “on”,“above”, “below”, “bottom”, “top”, “side” (as in “sidewall”), “higher”,“lower”, “upper”, “over”, and “under”, are defined with respect to thehorizontal plane.

Referring now to FIG. 1, therein is shown a portable computer 100 havinga housing base 102 that supports a keyboard 104 having keys 106, atouchpad 108, a release latch 110, and so forth. The housing base 102also supports conventional components (not shown) such as a powersupply, a microprocessor (“CPU”), a computer memory, a hard drive(“HD”), an optical disk drive (“ODD”), and so forth. A display 112 ishingedly attached to the housing base 102, and when closed is retainedin place by the release latch 110.

The portable computer 100 has several status indicators according to thepresent invention, as will be described in further detail below. Thesestatus indicators include, for example, a caps lock indicator 114, asleep indicator 116, status indicators 118, a power button 120, and soforth. The caps lock indicator 114 is located in the caps lock key 122of the keyboard 104 to indicate when the caps lock function of thekeyboard 104 has been engaged. The sleep indicator 116 is located in therelease latch 110 to indicate when the portable computer 100 has beenengaged in a sleep mode. The status indicators 118 may be used toprovide information concerning the status of any function or activityassigned thereto, for example, wireless link status, video camerastatus, low battery, battery charging, hard drive activity, and soforth. Similarly, the power button 120 can be illuminated to indicatethat the computer is powered on, or may be illuminated upon opening thedisplay 112 to assist in locating the power button 120, and so forth.

In prior computer configurations and designs, these various statusindicators are ordinarily visible to the user in both the activated (or“on”) and the inactivated (or “off”) states. In the on state, anindicator will characteristically be illuminated continuously orperiodically (e.g., cyclically), sometimes with a particularinformational color according to the status that the indicator isreporting. In the off state, the indicator will typically be darkened(inactivated or unilluminated), but unfortunately (in manycircumstances) can nonetheless still be seen. In the off state,therefore, the indicator often distracts and/or spoils the aesthetics ofthe portable computer 100.

In contrast, it is believed that a majority of consumers would find theportable computer 100 to be more attractive if status indicators of thissort became invisible in the off state. Of course, it will also beappreciated that there are other circumstances in which an indicator,such as a logo, would preferably remain visible even when in the offstate, and circumstances of that sort are also addressed hereinbelow.

Concerning status indicators that would ideally not be visible (i.e.,would disappear) in the off state, a principal difficulty faced byprevious techniques is that such status indicators are ordinarilylocated in a partially or completely opaque display surface area. Forthe status indicator to function, therefore, the surface is interruptedat the status indicator location so that the light from the statusindicator can be externally visible to the user. The consequent visiblediscontinuity in the appearance of the surface is therefore alwaysvisible to the user, whether the indicator is on or off.

There have been previous efforts to reduce or eliminate the visibilityof such status indicators when in the off state. One such priortechnique preserves the integrity of the display surface by reducing thethickness of a metallic display panel from the rear in the region orarea of the status indictor. The thickness is reduced until the metallicdisplay panel actually becomes light-transmissive. When light is thenshined on the rear or back side of the metallic display panel, it passesthrough that region and becomes visible on the opposite (outer or front)side of the metallic display panel. Thus, by thinning the metal onlyfrom the back side, the opposite side of the metallic display panelremains smooth, untouched, and uninterrupted. As such, the statusindicator region in the off or unilluminated state cannot bedistinguished and is invisible from the unmodified outside surface ofthe metallic sheet.

In one implementation of this technique, a matrix of holes was formedfrom and into one side (e.g., the “back side”) of a metal sheet nearlyto the surface of the other side (e.g., the “front side”). For example,using laser ablation on an aluminum sheet, the holes were formed fromthe back side of the metallic aluminum sheet until there was a thicknessof metal remaining at the front side on the order of only 12-20 nm. Thematrix of holes was configured in the shape of a desired indicator, suchas an arrow. The very small thickness of metal remaining at the end ofeach hole at the front surface of the metallic aluminum sheet allowedlight to pass outwardly through the front surface of the sheet when thelight was shined into the holes from the back surface thereof.

Unfortunately, such a reduced metallic thickness technique is veryexpensive due to the extreme precision required for the laser ablation(e.g., using a femtosecond laser) and the need for metallic sheetshaving a very even thickness and very even and flat surfaces. The needto have a perfectly flat metallic sheet can be somewhat mitigated byusing a camera or other light-detecting device that is directed at thefront surface of the metallic sheet in the vicinity where the holes arebeing laser-drilled from the back side of the sheet. The camera thendetects light from the laser just as the remaining metal at the end ofthe hole becomes light transmissive. Upon detecting the desiredintensity of light from the laser, the laser drilling process can thenbe terminated. However, this is a sensitive process and is veryexpensive.

Such reduced metallic thickness, light-through-metal status indicatorsare also fragile due to the very thin, easily damaged metallic membranesat the ends of the holes at the front surface of the metallic sheet.

Another disadvantage is that the amount of light transmitted is verysmall. For example, at 22 nm thickness of aluminum, only about onepercent of the light is transmitted; at 12 nm approximately six percentis transmitted. Thus, intense illumination is needed on the back side ofthe metallic sheet to provide an acceptably visible status indication onthe front surface.

The systems of the present invention overcome the numerous disadvantagesof previous techniques. They also provide new versatility, options, andcapabilities not achievable with previous techniques.

Referring now to FIG. 2A, therein is shown an enlarged detail from FIG.1 of the status indicators 118 according to the present invention. Thestatus indicators 118 are illustrated in the on or illuminated andvisible state.

Referring now to FIG. 2B, therein is shown a view similar to FIG. 2A inwhich the status indicators 118 are in the off or unilluminated state.As can be seen, the status indicators 118 in the off state have becomeinvisible. The surface of the display 112 in which the status indicators118 are located is smooth, continuous, uncluttered, and uninterrupted.

Referring now to FIG. 3A, therein is shown an enlarged detail from FIG.1 of the caps lock indicator 114 according to the present invention. Thecaps lock indicator 114 is illustrated in the on or illuminated andvisible state.

Referring now to FIG. 3B, therein is shown a view similar to FIG. 3A inwhich the caps lock indicator 114 is in the off or unilluminated state.As can be seen, the caps lock indicator 114 in the off state has becomeinvisible. The surface of the caps lock key 122 in which the caps lockindicator 114 is located is smooth, continuous, uncluttered, anduninterrupted.

Referring now to FIG. 4A, therein is shown an enlarged detail from FIG.1 of the sleep indicator 116 according to the present invention. Thesleep indicator 116 is illustrated in the on or illuminated and visiblestate.

Referring now to FIG. 4B, therein is shown a view similar to FIG. 4A inwhich the sleep indicator 116 is in the off or unilluminated state. Ascan be seen, the sleep indicator 116 in the off state has becomeinvisible. The surface of the release latch 110 in which the sleepindicator 116 is located is smooth, continuous, uncluttered, anduninterrupted.

The status indicators 118, the caps lock indicator 114, the sleepindicator 116, and other desired display patterns that disappear in theoff state, form “ghosted field” display patterns that appear anddisappear (like ghosts) when tamed on and off. As explained in greaterdetail hereinbelow, such invisible, light-transmissive display systemscan be provided for viewing at an outer surface of a light resistantmaterial. Such a light resistant material may be, for example, asubstantially opaque material such as metal, or a light-absorbing buttranslucent material such as colored plastic, or a coated or paintedmaterial, or material of other appropriate composition andconfiguration. As used herein, therefore, “light resistant” refers tosome degree of light attenuation, up to and including complete opacity.

Invisible holes are then penetrated in one or more desiredlight-transmissive display patterns through at least a portion of thelight resistant material to provide the ghosted field display patterns.

Referring now to FIG. 5A, therein is shown a bottom view of the portablecomputer 100 of FIG. 1. Accessible on the bottom 502 of the portablecomputer 100 is a battery pack 504 having battery status indicatorlights 506. In one embodiment, for example, a test button 508 on thebattery pack 504 can be actuated to cause the battery status indicatorlights 506 to illuminate according to the charge state of the batterypack 504. The more battery status indicator lights 506 that illuminate,the higher the charge level of the battery pack 504. FIG. 5A illustratesthe indicator state in which all five of the battery status indicatorlights 506 are illuminated, showing a fully charged battery.

Referring now to FIG. 5B, therein is shown a detail from FIG. 5A inwhich the battery status indicator lights 506 are in the off orunilluminated state. However, although the battery status indicatorlights 506 are off, they have not become invisible. Rather, in somesituations, it may be desirable for a status indicator to remain atleast partially visible when in the off state. For example, the batterystatus indicator lights 506 number five such indicators. Sometimes,actuation of the test button 508 will cause only some (or none) of thebattery status indicator lights 506 to illuminate, thereby indicating acorresponding partially charged (or discharged) state for the batterypack 504. In such a case, it can be desirable for the remaining batterystatus indicator lights 506 that are in the off state to be visible sothat the user can easily see what proportion is illuminated. Thus, asillustrated in FIG. 5B, the battery status indicator lights 506 are allin the off state but remain visible.

The persistent visibility for the battery status indicator lights 506(or any other desired status indicators) when in the off state may beachieved, for example, by providing a different surface treatment on thesurface where the status indicators are located, or, for example,heating the surface during formation of the status indicatorssufficiently to discolor or even slightly bum the surface, to achievethe desired effect. Or, the surface may be colored such as byapplication of a paint, color, or dye in the desired pattern.Alternatively, or in addition, the status indicator through-the-surfacelight-conducting invisible holes (as explained below starting with thedescription of FIG. 7) may include additional holes of visible sizeand/or include clear coat formulations that contrast with the surfacewhere the status indicators are located. In this way, the locations andstates of the indicators are always visible, even though the principlemeans by which the light is actually able to emanate from the displaysurface (i.e., the invisible holes) cannot be seen.

Referring now to FIG. 6A, therein is shown a personal music player 600.A logo 602 is provided as an intrinsic, visible design on a surface ofthe personal music player 600, and is shown in the on (illuminated)state. Utilizing the invisible hole technology of the present invention(explained further hereinbelow), the light from the logo 602 emanatesfrom the surface of the personal music player 600 with no visiblesource. To the unaided eye, the surface of the logo appears continuous,solid, metallic, and seemingly incapable of transmitting light. Thiscontinuous, uninterrupted and unblemished surface, which neverthelessemits light, is accordingly particularly aesthetically appealing.

Referring now to FIG. 6B, therein is shown a detail from FIG. 6A showingthe logo 602 in the off (unilluminated) state. Unlike the statusindicators of the present invention that disappear in the off state(e.g., the status indicators 118 (FIG. 2B), the caps lock indicator 114(FIG. 3B), and the sleep indicator 116 (FIG. 4B)), the logo 602, asdepicted in FIG. 6B, remains visible in the off state (like the batterystatus indicator lights 506 (FIG. 5B)). Accordingly, depending upon theimplementation of the present invention (as detailed more particularlyhereinbelow), a wide variety of effects and treatments can be providedas desired. Thus, as depicted in FIG. 6B, the unilluminated logo 602 maybe configured to appear as a logo that is etched into a solid metallicsurface. Then, upon illumination of the logo 602 from behind, lightemanates from the seemingly solid metallic surface of the logo 602, asdepicted in FIG. 6A, realizing a particularly attractive and dramaticeffect.

Referring now to FIG. 7, therein is shown an enlarged view of a fragment700 of light resistant material having an opaque outer surface 702according to an embodiment of the present invention. In one embodiment,the opaque outer surface 702 is the outer surface of a metallic sheet ofaluminum. Holes 704 are formed in and penetrate through the opaque outersurface 702 to the opposite or inner side (i.e., the rear surface 804shown in FIG. 8) of the fragment 700.

The holes 704, although shown greatly exaggerated in the drawing FIGs.,are actually invisible. That is, each of the holes 704 is smaller thanresolvable by an unaided human eye. For example, the limit of resolutionfor the human eye is about 0.1 mm at a distance from the eye of 1 meter.In children, the resolution might be somewhat finer, for example, 0.04mm. Thus, depending upon the anticipated viewer and viewing distance,the holes 704 will be selected to be below the limit of resolution, andit will accordingly be understood that the term “invisible hole” refersto this upper limit. Thus, as defined herein, “invisible holes” refersto holes that arc smaller than resolvable by an unaided human eye.

Conversely, it will be understood that the term “visible holes” refersto holes that are large enough to be resolvable by an unaided human eye.

As depicted in FIG. 7, the holes 704 are arranged in a pattern 706 thatforms a status indicator shaped as a circle or dot. For expositoryreasons, just as the holes 704 are shown greatly exaggerated in size, soalso is the size of the pattern 706 greatly exaggerated. Typically,however, the pattern 706 will be large enough to be seen (whenilluminated) by the unaided human eye—such as of the size ofconventional status indicators.

In one embodiment in which the holes 704 are utilized to form statusindicators for a portable computer such as the portable computer 100(FIG. 1), the holes 704 have a diameter of 0.02 mm. Spacings between theholes 704 are a distance of 0.18 mm. The size of the status indicatorpattern itself (e.g., the pattern 706) varies from a fraction of a mm toseveral mm across, depending upon the actual pattern that is depicted.

Referring now to FIG. 8, therein is shown a cross-sectional view 800 ofthe fragment 700, taken on line 8-8 in FIG. 7. In this embodiment,formation of the holes 704 is facilitated by forming a cavity 802 in therear surface 804 of the fragment 700. The cavity 802 is thus oppositethe opaque outer surface 702 for the pattern 706 (FIG. 7) statusindicator. Advantageously, the cavity 802 significantly reduces theamount of drilling that must be performed to form the holes 704 throughthe opaque outer surface 702.

A light source such as a light 806 is located opposite or within thecavity 802 and configured for providing light to be transmitted throughthe holes 704 when the pattern 706 status indicator is actuated to theon state.

It will be appreciated, of course, that in certain situations the cavity802 can be advantageous, while in others it may not improve overallmanufacturing efficiency or speed. For example, when the fragment 700 isnot particularly thick (e.g., on the order of up to 0.7 mm or so ofaluminum), the additional time for laser drilling a pattern of holessuch as the holes 704 may increase by only a few seconds to less than aminute. In such a case, it may be more efficient and economical to omitthe cost and delay associated with first forming the cavity 802.

Referring now to FIG. 9, therein is shown the structure of FIG. 8following application of a clear coat 902 into the holes 704. The clearcoat 902 may be any suitable clear or translucent coating or material,such as a clear paint, that functions as a light-conductive filler.Depending upon the particular application and configuration at hand,such a clear coat 902 may be water based and cured by water evaporation,or polymer based and cured by ultraviolet (“UV”) light, heat curable,and so forth, as is known in the liquid coating arts.

The clear coat 902 is selected to wet the surface of the holes 704appropriately for the material in which the holes 704 are formed. In oneembodiment, a UV curable clear coat 902 having a viscosity (when liquid)matched to the dimensions and materials of the holes 704 was painted orsprayed upon the opaque outer surface 702, allowing the natural surfacetension properties and capillary action of the clear coat liquid to drawthe clear coat 902 into the holes 704. Thereafter, the clear coat 902was appropriately cured. Depending upon the circumstances of theparticular application in which the present invention is being utilized,the clear coat 902 may be applied from the opaque outer surface 702, therear surface 804, or both surfaces.

It has been discovered that the clear coat 902 provides several aspects.For example, it closes and seals off the holes 704, protecting them fromingress of dirt, oil, and other contaminants that might degrade thelight transmissivity thereof. The outer surface is thus secured in caseof exposure to contamination.

The clear coat 902 can also be modified or adjusted to provide desiredeffects concerning the light that is being transmitted through the holes704. For example, the clear coat 902 may be provided with a desiredcolor, such as by incorporating a corresponding color, dye, orfluorescent dye thereinto. Alternatively or additionally, particles 904may be provided or incorporated into the clear coat 902. Such particlesmay also be colored to provide various desired effects with regard tothe color qualities of the light issuing from the holes 704. Theseparticles may include, for example, nano-size reflective metallicparticles, silicon particles, mica particles, fluorescent particles, andso forth. Such particles 904 are advantageous, for example, when it isdesired to disperse the light emanating from the holes 704 over a widerviewing angle. Conversely, due to the collimating effect of the holes704 upon the light from the light 806, the visibility of the lightemanating from the holes 704 can be advantageously restricted to anarrow viewing angle nearly perpendicular to the opaque outer surface702 by using a clear coat 902 that does not contain light scatteringelements, but may still include one or more colors or dyes if desired.

Examples of light-conducting clear coats 902 used as fillers for themicro-perforated holes 704 penetrated through aluminum plates are in thetable below. The aluminum plates were anodized aluminum measuring 7inches×4 inches×4 mm. Small, medium, and large holes, ranging in sizefrom 20 μm to 60 μm, were penetrated through the plates and filled withclear coat applied from the inner surfaces of the plates. The first setof holes received just a clear coat; the second a clear coat containing2% fluorescent pigment; the third a clear coat containing 2% siliconparticles of nano size.

The clear coats were applied on top of the holes by small brushes(thereby causing the clear coats to have the characteristics of havingbeen brushed into the invisible holes), and just enough time was allowedto let the clear coats penetrate and flow to the outer (or front)surfaces of the aluminum plates, following which the clear coats were UVcured. The clear coat penetration times were determined byexperimentation. It was discovered that hole penetration times could benormalized by using and correlating higher clear coat viscosities onlarger holes and corresponding lower viscosities on smaller holes.

Following satisfactory penetration, the aluminum plates were passed intoa UV curing oven in which both sides of the plates were cured. The UVenergy used was 72 milli-Joules for two curing cycles of 10 secondseach.

UV Viscosity Penetration Curing Hole (millipoise) time time diameterClear coat at 25° C. in seconds in seconds 20 μM Urethane Oligomer 260020 2 × 10 Epont Cure 2000-101-A 30 μM Urethane Oligomer 2600 10 2 × 10Epont Cure 2000-101-A 8O μM  Urethane Oligomer 5800 8 2 × 10 Epont Cure2000-100-A 20 μM 2000-101-A + 2% 2600 25 2 × 10 Flouroscent 30 μM2000-101-A + 2% 2600 12 2 × 10 Flouroscent 80 μM 2000-100-A + 2% 5800 102 × 10 Flouroscent 20 μM 2000-101-A + 2% 2600 25 2 × 10 Si Nano 30 μM2000-101-A + 2% 2600 12 2 × 10 Si Nano 80 μM 2000-100-A + 2% 5800 10 2 ×10 Si Nano

Following completion of the hole filling process, a light source wasshined on the back surface of each aluminum plate. The light sourceshowed that the larger holes were brighter than the smaller ones. At aviewing angle of about 15 degrees, the light transmitted was alsobrighter with the clear coats that had a fluorescent pigment, a littleless bright with the clear coats that had nano particles, and even lessbright with the clear coat only. Thus, the fluorescent pigment and thenano particles both helped to increase the angle and the intensity ofthe transmitted light. Additionally, the clear coats scaled the holes toprevent dirt and contaminants from entering the holes.

Referring again to FIG. 9, when the fragment 700 is optionally providedwith the cavity 802, a structural plug 906 (for example of clearplastic) may then be inserted into the cavity 802. A suitable adhesiveor an adhesive tape 908 may be used to secure the structural plug 906 inthe cavity 802. The structural plug 906 then provides structuralreinforcement at the rear of the holes 704. This additional structuralreinforcement can be advantageous because of the reduced thickness andstructural strength of the fragment 700 in the vicinity of the holes704, and because of the further reduction in strength caused by theholes 704 themselves. The structural plug 906 thus reduces thelikelihood of damage to the indicator or logo (as the case may be) thatis formed by the pattern of the holes 704, should force be inadvertentlyapplied thereto from the outside.

As illustrated in FIG. 9, the structural plug 906 conforms substantiallyto the dimensions of the cavity 802, with perhaps a slight clearance orgap therebetween for ease of assembly. The clearance or gap shown inFIG. 9 is exaggerated for clarity of illustration.

In view of the teachings herein, it will also be understood that atransparent or translucent structural reinforcing element, like thestructural plug 906, may be used to reinforce any portion of alight-transmissive display pattern, such as an indicator or logo area,of the present invention, whether or not a cavity such as the cavity 802is present. This could be advantageous, for example, for a large logowherein such a large number of the holes 704 would be formed that thestructural integrity of the area would be reduced even in the absence ofthe cavity 802.

Referring now to FIG. 10, therein is shown the structure of the fragment700 in FIG. 9 provided with individual lights 1002, one for each of theholes 704, rather than the light 806 (FIG. 9) that was common to all theholes 704. The individual lights 1002 are depicted representationally,it being intended and understood that the individual lights 1002 may beprovided in a medium that is either discrete or continuous according tothe particular application and needs at hand. Thus the individual lights1002 may be, for example, individual light-emitting diodes (“LEDs”),light sources from a discrete or continuous organic light-emitting diode(“OLED”) structure, or other individual light sources or emitters indiscrete or continuous media as appropriate.

The individual lights 1002 can be individually controlled, for exampleby a CPU 1004 or other suitable controller responding in known fashionto appropriate programming or user input. Thus, it is possible to pairthe holes 704 with corresponding individual lights 1002 to formindividually controllable pixels. When aggregated together, theseindividual hole-light pixels form a controllable and changeable display.In this manner, by matching the pixel pitch of the individual lights1002 with the micro-perforated pattern of the holes 704, an invisible,programmable display can be made to appear through an apparently solidsurface such as the opaque outer surface 702.

The individual lights 1002 are thus light sources that are configuredand oriented behind the opaque outer surface 702 (metallic, plastic,coated, or otherwise) and are respectively aligned with the invisibleholes 704. The holes 704 in this embodiment are invisible. Theindividual lights 1002 are then configured to controllably shinepredetermined patterns of monochrome or multi-colored light through theinvisible holes to cause the holes 704 to function as pixels to providea controllable visual display through the seemingly solid surface. Byvirtue of the CPU 1004 (or other suitable mechanism) it is also possibleto then choose and customize aesthetic and display motifs by selectingand controlling the light and light patterns that are displayed throughthe invisible holes 704.

It will now also be clear to one of ordinary skill in the art that theseteachings may be combined as desired, such that, for example, a singleor a limited number of monochrome or multi-colored light sources may beused to provide a visual display by shining the light through aselectively transmissive matrix. For example, the light may be shinedthrough a liquid crystal display (“LCD”) or a thin film transistor(“TFT”) display having pixels aligned with respective individualinvisible holes such as the holes 704.

Referring now to FIG. 11, therein is shown such a combined configuration1100. In this embodiment, a light source 806 is positioned behind a TFTlayer 1102. The individual pixels 1104 of the TFT layer 1102 are alignedwith respective individual holes 704 to selectively and controllablyshine predetermined patterns of monochrome or multi-colored lightthrough the holes 704, as desired. From the perspective of the holes704, each of the individual pixels 1104 is configured as a light sourcealigned with its respective corresponding hole 704. In the aggregate,therefore, patterns of monochrome or multicolored light can becontrollably shined through the holes 704 to cause the holes 704 tofunction as pixels to provide a controllable visual display.

It will also now be clear that the holes 704 can be utilizedbi-directionally for receiving light as well as transmitting it. Thus,for example, the individual lights 1002 (FIG. 10) or the TFT layer 1102,for example, may also be configured to detect as well as transmit light,or even just to detect light. Such light detectors may serve, forexample, for receiving external control inputs for a processor,controller, or other device, such as the CPU 1004 (FIG. 10).

Referring now to FIG. 12, therein are shown several representative holepatterns 1200 of the holes 704. For clarity of illustration, the holes704 are shown greatly exaggerated in size, and for expository reasons,are shown generally much fewer in number than would be expected in atypical implementation. Thus, for instance, hole pattern 1202 forms asquare, or “stop” indicator. Hole pattern 1204 forms a right-facingtriangle, or “play” indicator. Hole pattern 1206 forms two verticalparallel lines, or a “pause” indicator. Hole pattern 1208 forms a doubleright pair of triangles, or a “fast forward” indicator. Hole pattern1210 forms a double left pair of triangles, or a “rewind” indicator.Hole pattern 1212 forms a double right pair of triangles toLlchmg avertical bar, or a “skip forward” indicator. Hole pattern 1214 forms adouble left pair of triangles touching a vertical bar, or a “skipbackward” indicator. Hole pattern 1216 forms an arrow reversing towardthe left, or a “return” indicator. Hole pattern 1218 forms a left-facingtriangle adjacent a vertical bar, or a “section backup” indicator. Holepattern 1220 forms a right-facing triangle next to a vertical bar, or a“section forward” indicator. Hole pattern 1222 forms a round dot that isfrequently used, for example, for an “on” or “enabled” indicator.

It has been unexpectedly discovered that the invisible,light-transmissive display system of the present invention providesexceptional versatility and choice in the presentation of displays. Forexample, in order to make the displays virtually invisible when thestatus indicators are in the off status, as illustrated for example inFIGS. 2B, 3B, and 4B, various surface effects and/or filler effects canbe employed. That is, for example, with a smoothly polished (e.g.,mirror finished) opaque outer surface 702 (such as illustrated in FIG.6A), the presence of the holes 704 can sometimes be noticed because theholes will be slightly less reflective. The holes 704 will thereforecause such a polished surface to appear slightly duller where the holesare located even though the holes themselves are not visible.

One way to compensate for the slightly less reflective properties of theholes, according to the present invention, is to provide a texturedrather than smoothly polished surface (as also illustrated in FIG. 7).The surface may be textured such as by burnishing, etching,sandblasting, anodizing, engraving, and so forth.

Another approach for disguising the presence of the holes, as taughtherein, is to include particular particles 904 (FIG. 9) in the clearcoat 902 in the holes 704. Such particles can be selected to reflectlight in a complimentary manner to the opaque outer surface 702, thusdiminishing the light-attenuating effects of the holes 704. For example,the particles 904 may be nano-particles formed of the same material as,or of a material similar in color and appearance to, the opaque outersurface 702. In this fashion, the particles 904 will tend to reflectlight in a complimentary manner to the opaque outer surface 702, therebydiminishing the light-attenuating or light-changing effects of the holes704 relative to the opaque outer surface 702.

Of course, based on these teachings, it will now be clear to one ofordinary skill in the art that these various solutions may be combined.For example, suspended nano-particles may be combined with texturedsurrounding surfaces to provide even greater camouflage for the presenceof the invisible holes.

It has also been unexpectedly discovered that various surface effects,such as simulated etching, can be achieved by combining differentlysized holes, different hole spacings, different fillers, different lightsources, different surface finishes, and combinations of these, asdesired. According to the desired effect, it will now be understood,therefore, that larger, visible holes may be employed along with theinvisible holes to achieve unexpected, sometimes dramatic effects. Theseeffects include, for example, smooth shading, gradual or abrupt changesin texture, and so on, as the mix of these variable features changesfrom one location to another. An example of one such complex combinationof these effects is illustrated in FIGS. 6A and 6B.

Also, the hole patterns may be selectively illuminated in order tochange the particular pattern that is presented at any given time. Forexample, the pattern 1220 (FIG. 12) may also be used to form the pattern1204 by not illuminating the vertical bar in the pattern 1220.Similarly, the patterns 1212 and 1214 may be utilized in like manner toform, respectively, the patterns 1208 and 1210. In the same way, subsetsof patterns similar to the patterns 1202 and 1222 can be used forforming other hole patterns such as, for example, the patterns 1204,1206, and so forth.

The present invention also unexpectedly affords great versatility sinceit is highly adaptable to implementation by many existing technologies.For example, the invisible holes may be penetrated in the variouslight-transmissive display patterns through the opaque metallic,plastic, coated, or other light resistant material using one or more oflaser drilling, laser machining, electron beam machining,electro-discharge machining (“EDM”), chemical milling, metal injectionmolding, conventional drilling, and a combination thereof, along withother suitable technologies as may be appropriate for the particularapplication at hand. Invisible holes that arc formed thus will have thecharacteristics of the respective processes that were used to form them.

It will also be understood and appreciated by those of ordinary skill inthe art, based on this disclosure, that the hole spacings and sizes, assuggested above, need not be as uniform as they are illustrated in thedrawing FIGs. Variable spacings and sizes may be used to achieveeffects, such as differences in texture, gradations in brightness, andso forth. It will also be understood that although the holes 704 areshown in FIGS. 8-10 as having uniformly cylindrical cross-sectionalprofiles, this is for illustrative purposes only, and that the holes intypical implementations will be expected to have the characteristictaper of the process that was used to form them. For example,laser-drilled holes often have a narrower or waisted portion toward thecentral longitudinal portion thereof, whereas holes formed by EDM tendto be very uniform in diameter.

Referring now to FIG. 13, therein is shown a flow chart of a process1300 for manufacturing an invisible, light-transmissive display system1300 in accordance with an embodiment of the present invention. Theprocess 1300 includes providing a light resistant material in a block1302; and penetrating substantially invisible holes in a predeterminedlight-transmissive display pattern through at least a portion of thelight resistant material in a block 1304.

It has been discovered that the present invention thus has numerousaspects.

A principle aspect that has been unexpectedly discovered is that thesystem of the present invention can economically and unobtrusivelyprovide highly effective, aesthetically pleasing, and highly desirablesurface displays that can be made invisible when not activated.

Another aspect is that the system of the present invention can providefor light emanation from an apparently solid, surface, with or withoutan intrinsic, visible design in that surface area.

Another important aspect is that the system of the present invention canbe utilized with great success and effect with materials as describedabove that are not entirely opaque. Thus, invisible, light-transmissivedisplay systems can be provided for viewing at an outer surface, notonly of substantially opaque materials, but also of materials that arenot opaque. A light resistant material that nevertheless allows somelight to pass through, such as a translucent colored plastic, canfurnish the basis for very dramatic display systems according to thepresent invention. Thus, in view of the teachings herein, it will now beclear to one of ordinary skill in the art that the invisible holes andsystems according to the present invention, penetrated in a desiredlight-transmissive display pattern through at least a portion of lightresistant material, will cause much brighter (and pleasingly unexpected)display patterns than if shined through materials that lack the presentinvention.

Another aspect is that the system of the present invention can be usedfor an extensive variety of desired displays, such as informationalpatterns, logos, control indication patterns, status indicationpatterns, directive patterns, artistic patterns, and so forth.

Yet another aspect is that the system of the present invention makes itpossible to provide for and to enable the user to choose and thuscustomize aesthetic and display motifs according to individualpreferences, by selecting and controlling the light and light patternsthat are displayed through the invisible holes.

Another aspect is that the system of the present invention can provideselectable illumination through visible and otherwise apparently soliddisplays, designs, patterns, indicators, logos, and so forth.

Another aspect is that the system of the present invention can be usedwith virtually any kind of device needing or benefiting from anilluminated display configuration, such as computers, display panels,personal data assistants, personal music players, applianceinstrumentation, vehicle instrumentation, a vehicle display, electronicsinstrumentation or display, jewelry, interactive kiosks, automatedtellers, communication devices (such as cell phones, wired and wirelesstelephones, walkie-talkies, etc.), remote control devices, medicalinstruments or devices, training simulators, and so forth.

Another aspect is that the present invention allows displays to beprovided in a fully metallic surface, thereby reducing vulnerability andimproving the durability and robustness thereof.

Yet another important aspect of the system of the present invention isthat it valuably supports and services the historical trend of reducingcosts, simplifying systems, and increasing performance.

These and other valuable aspects of the present invention consequentlyfurther the state of the technology to at least the next level.

Thus, it has been discovered that the invisible, light-transmissivedisplay system of the present invention furnishes important andheretofore unknown and unavailable solutions, capabilities, andfunctional aspects for display systems for electronic and other devices.The resulting configurations are straightforward, cost-effective,uncomplicated, aesthetically pleasing and attractive, highly versatileand effective, can be surprisingly and unobviously implemented byadapting known technologies, and arc thus readily suited for efficientlyand economically manufacturing highly desirable and appealing invisibledisplay systems.

While the invention has been described in conjunction with a specificbest mode, it is to be understood that many alternatives, modifications,and variations will be apparent to those skilled in the art in light ofthe aforegoing description. Accordingly, it is intended to embrace allsuch alternatives, modifications, and variations that fall within thescope of the included claims. All matters hithertofore set forth hereinor shown in the accompanying drawings are to be interpreted in anillustrative and non-limiting sense.

What is claimed is:
 1. An electronic device, comprising: an electronicdevice housing having openings, wherein each of the openings has a widththat is less than 100 microns; light sources mounted within theelectronic device housing; and control circuitry that is configured tocontrol the light sources to selectively transmit light through a subsetof the openings.
 2. The electronic device defined in claim 1, whereinthe control circuitry is further configured to control the light sourcesto adjust the subset of the openings through which the light istransmitted.
 3. The electronic device defined in claim 2, wherein subsetof the openings forms an illuminated pattern at a surface of theelectronic device housing.
 4. The electronic device defined in claim 3,wherein the illuminated pattern comprises a control indication pattern.5. The electronic device defined in claim 3, wherein the illuminatedpattern comprises a status indication pattern.
 6. The electronic devicedefined in claim 1, wherein the subset of the openings forms a circularpattern at the surface of the electronic device housing.
 7. Theelectronic device defined in claim 1, wherein the subset of the openingsforms a rectangular pattern at the surface of the electronic devicehousing.
 8. The electronic device defined in claim 1, wherein theelectronic device housing comprises a metal electronic device housingwall that defines the openings.
 9. The electronic device defined inclaim 1, wherein each of light sources transmits the light through adifferent respective one of the openings.
 10. The electronic devicedefined in claim 9, wherein the light sources comprise first and secondlight sources, the openings comprise first and second openings, thefirst light source is configured to emit light of a first color that istransmitted through the first opening, and the second light source isconfigured to emit light of a second color that is different from thefirst color and that is transmitted through the second opening.
 11. Theelectronic device defined in claim 1, wherein the openings comprisefirst and second openings, the electronic device further comprising: afirst filler material in the first opening that transmits light of afirst color; and a second filler material in the second opening thattransmits light of a second color that is different from the firstcolor.
 12. An electronic device, comprising: a structure having asurface, wherein the structure defines an opening having a lateraldimension at the surface that is less than 100 microns; a light detectorthat detects light received through the opening; and control circuitrythat receives a control input that is generated based on the lightdetected by the light detector.
 13. The electronic device defined inclaim 12, wherein the structure comprises an electronic device housingin which the light detector and the control circuitry are mounted. 14.The electronic device defined in claim 13, wherein the electronic devicehousing comprises a metal housing wall and the surface comprises anexterior surface of the metal housing wall.
 15. The electronic devicedefined in claim 12, further comprising: a light source that transmitslight through the opening.
 16. The electronic device defined in claim12, wherein the structure further defines an additional opening having alateral dimension at the surface that is less than 100 microns, theelectronic device further comprising: a light source that transmitslight through the additional opening.
 17. The electronic device definedin claim 16, wherein the opening is configured to transmit light of afirst color and the additional opening is configured to transmit lightof a second color that is different from the first color.
 18. Theelectronic device defined in claim 12, wherein the structure furtherdefines an additional opening having a lateral dimension at the surfacethat is less than 100 microns, the electronic device further comprising:an additional light detector that detects light received through theadditional opening.
 19. The electronic device defined in claim 18,wherein the opening is configured to transmit light of a first color andthe additional opening is configured to transmit light of a second colorthat is different from the first color.
 20. An electronic device havingopposing first and second sides, the electronic device comprising: ametal housing, wherein the first side of the electronic device has asurface that is defined at least partially by the metal housing; anopaque layer on the second side of the electronic device, wherein theopaque layer defines an opening that is less than 100 microns across;and a light detector mounted within the metal housing that detects lighttransmitted through the opening.
 21. The electronic device defined inclaim 20, wherein the opening comprises one of a plurality of openingsthat are defined by the opaque layer and that are each less than 100microns across, wherein the light detector comprises one of a pluralityof light detectors, and wherein each light detector of the plurality oflight detectors detects light transmitted through a different respectiveopening of the plurality of openings.